Brother HL-4040CN Owner's manual

TN-110BK 2500 pages at 5% cover
TN-110C 1500 pages at 5% cover
TN-110M 1500 pages at 5% cover
TN-110Y 1500 pages at 5% cover
TN-115BK 5000 pages at 5% cover
TN-115C 4000 pages at 5% cover
TN-115M 4000 pages at 5% cover
TN-115Y 4000 pages at 5% cover
HL4040TECH
Phillips screwdriver
Small flat blade
screwdriver
Needle nose pliers
Pliers
Supplies Required:
Toner
BR1240FILLCAP
REV. 11/12/08
PHOTO 1
PHOTO 2
PHOTO 3
HL-4040CN 21 PPM
HL-4070CDW 21 PPM
MFC-9440CN 21PPM
MFC-98CDW 21PPM
DPC-9040 21PPM
DCP-9045CDN 21PPM
Step 1
Set the hopper on a work bench with the
toner hopper handle facing towards you.
Take a flat blade screwdriver and remove
the handle hinges that hold the toner hopper
handle onto the toner hopper (See photos 1
& 2).
Step 2
Using a Phillips screwdriver, remove the two
screws that hold the gear housing end cap
to the toner hopper (See photo 3).
Technical Instructions Printers Cartridge Info Tools 1
E-mail: [email protected] Website: www.fgimaging.com
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© 2008 Future Graphics Imaging Corporation. All rights reserved. Future Graphics Imaging Corporation (FGIC) is a distributor of compati-
ble replacement parts and products for imaging equipment. None of FGIC's products are genuine OEM replacement parts and no affiliation
or sponsorship is to be implied between FGIC and any OEM.

Step 3
Holding the toner hopper so the top
is facing you, use a flat blade screw-
driver to release the gear end cap
tab that holds the end cap to the
side of the hopper (See photo 4).
Remove gear end cap (See photo 5).
© 2008 Future Graphics Imaging Corporation. All
rights reserved. Future Graphics Imaging
Corporation (FGIC) is a distributor of compatible
replacement parts and products for imaging equip-
ment. None of FGIC's products are genuine OEM
replacement parts and no affiliation or sponsorship
is to be implied between FGIC and any OEM.
Step 6
Remove the drive gear from the end of the
developer roller gear shaft (See photo 8).
Step 5
Using a flat blade screwdriver, remove the
“E” clip from the developer roller drive gear
shaft (See photo 7).
PHOTO 7
PHOTO 8
Step 7
Insert a small flat blade screwdriver
between the side wall of the toner hopper
and the white bearing tab. Rotate the white
bearing tab upward to unlock the developer
roller from the toner hopper (See photo 9).
PHOTO 9
Step 8
Rotate the cartridge 180°. Using a small flat
blade screwdriver, pry off the white plastic
alignment hub from the non-gear side of the
developer roller (See photo 10).
NOTE: Do not lose the tension spring that
sits behind the white plastic alignment
hub.
PHOTO 10
2 Brother HL-4040CN Technical Instructions
PHOTO 4
PHOTO 5
Step 4
Remove the reset spring, gears and the
developer roller support hub from the side
of the toner hopper (See photo 6).
PHOTO 6

Step 9
Using a Phillips screwdriver, remove the
screw that holds the developer roller bear-
ing end cap (See photo 11).
Step 10
Using a small flat blade screwdriver, pry off
the developer roller bearing end cap from
the developer roller axle (See photo 12).
PHOTO 11
PHOTO 12
PHOTO 14
Step 12
Clean the developer roller using a dry, lint-
free cloth and set it aside (See photo 15).
PHOTO 16
Step 13
Using a Phillips screwdriver, remove
the two screws that hold the doctor
blade onto the toner hopper (See
photo 16). Remove and clean the
doctor blade by using dry com-
pressed air and then a dry lint-free
cloth. Set doctor blade aside.
PHOTO 17
Step 14
Remove the toner fill plug with a pair
of pliers (See photo 17). Dump out
the toner from the toner hopper and
clean it with dry compressed air or a
vacuum.
NOTE: OEM fill plugs get damage
most of the time and may need to
be replaced.
© 2008 Future Graphics Imaging Corporation. All
rights reserved. Future Graphics Imaging
Corporation (FGIC) is a distributor of compatible
replacement parts and products for imaging equip-
ment. None of FGIC's products are genuine OEM
replacement parts and no affiliation or sponsorship
is to be implied between FGIC and any OEM.
PHOTO 13
PHOTO 15
Step 11
Lift the developer roller from the toner hop-
per (See photo 13). Slide out the white bear-
ing tab from the developer roller shaft (See
photo 14).
Brother HL-4040CN Technical Instructions 3

PHOTO 18
Step 15
Set the doctor blade onto the toner
hopper and install the two screws
that hold the doctor blade in place
(See photo 18).
Note: To prevent toner leaks from
the sides of developer roller, the
felts must be fluffy.
© 2008 Future Graphics Imaging Corporation. All
rights reserved. Future Graphics Imaging
Corporation (FGIC) is a distributor of compatible
replacement parts and products for imaging equip-
ment. None of FGIC's products are genuine OEM
replacement parts and no affiliation or sponsorship
is to be implied between FGIC and any OEM.
Step 17
Install the developer roller bearing end cap
onto the side of the toner hopper and install
the Phillips screw that holds it in place (See
photo 21).
PHOTO 19
PHOTO 21
Step 18
Install the tension spring and the white plas-
tic alignment hub to the developer roller
shaft (See photo 22).
PHOTO 22
Step 19
Install the developer roller drive gear to the
driver shaft of the developer roller, Place the
“E” clip onto the drive shaft of the develop-
er roller. Use a needle-nose pliers to snap
the “E” clip back into place (See photo 23).
PHOTO 20
Step 16
Slide in the white bearing tab to the devel-
oper roller drive shaft (See photo 19). Place
the developer onto the toner hopper and
rotate the white bearing tab until it locks into
its position (See photo 20).
PHOTO 23
4 Brother HL-4040CN Technical Instructions

Step 21
Place the gear end cap onto the toner hop-
per and install the two Phillips screws (See
photo 25).
Step 23
Install the cartridge handle and secure the
cartridge handle hinges into place (See pho-
tos 28 & 29).
PHOTO 24
PHOTO 25
PHOTO 26
PHOTO 27
PHOTO 29
PHOTO 30
Step 24
Install developer roller cover (See
photo 30).
NOTE: If cartridge is post tested
the reset gear must be reset after
post test.
© 2008 Future Graphics Imaging Corporation. All
rights reserved. Future Graphics Imaging
Corporation (FGIC) is a distributor of compatible
replacement parts and products for imaging equip-
ment. None of FGIC's products are genuine OEM
replacement parts and no affiliation or sponsorship
is to be implied between FGIC and any OEM.
PHOTO 28
Brother HL-4040CN Technical Instructions 5
Step 22
Fill the toner hopper and install a new toner
fill plug (See photos 26 & 27).
Step 20
Reinstall the train drive gears and the devel-
oper roller support hub.Install the ‘toner
out’ reset gear and the tension spring. The
long part of the spring attaches to the top of
the reset flag and the short part to the back
support post (See photo 24).

E-mail: [email protected] Website: www.fgimaging.com
© 2008 Future Graphics Imaging Corporation. All rights reserved. Future Graphics Imaging Corporation (FGIC) is a distributor of compatible replacement parts and products for imag-
ing equipment. None of FGIC's products are genuine OEM replacement parts and no affiliation or sponsorship is to be implied between FGIC and any OEM.
DEFECT CHART
OPC Drum ........................5mm
Developer Roller ................42.7mm
COMPOTES APPROXIMATE LIFE
Drum Unit ..........................17,000 pages
Waste toner box ................20,000 pages
Belt unit ............................50, 000 pages
Laser unit ..........................100,000 pages
Paper feeding kit ..............100,000 pages
Paper feeding kit MP ........50,000 pages
PHOTO 31
TN-110
PHOTO 32
TECHNICAL TIPS:
Do not mix TN-110 and TN-115 end
caps and gears. End caps and gears
are distinctive for each model. See pho-
tos 31 for TN-110 and 32 for TN-115.
TN-115